Side seam envelope

ABSTRACT

An envelope formed from a single blank with a front panel, rear panel, two side flaps, and a closure flap. The two side flaps are folded inward and an adhesive layer is secured to the two side flaps and the closure flap. The adhesive layer extends to at least the top perimeter of the two side flaps and may even extend beyond the top perimeter of the rear panel to include the front panel and even some portion of the closure flap. The rear panel is folded and secured along substantially the entire length of the two side flaps. The envelope is then exemplary placed under a drier to dry any of the adhesive that extends beyond the upper perimeter of the two side flaps and the upper perimeter of the rear panel. The envelope is then processed and stacked using conventional equipment.

CROSS RELATED APPLICATIONS

[0001] This application claims the benefit of provisional applicationNo. 60/469,973 filed on May 13, 2003.

BACKGROUND OF THE INVENTION

[0002] This invention relates to an envelope and method of forming anenvelope with a front panel, rear panel, two side seam flaps and aclosure flap.

[0003] It is well known to form envelopes from envelope blanks usingmechanical equipment. FIG. 1 illustrates a conventional blank 100 forforming a conventional envelope as described below. The blank 100comprises a four-sided front panel 20 with a perimeter defined by sides18, 22, 26, 28. A four-sided rear panel 10 with a perimeter defined bysides 12, 14, 16, 18 is secured to the front panel 20 along side 18. Afour-sided first side seam flap 30 with a perimeter defined by sides 32,34, 22, 38 is secured to one side of the front panel 20. A four-sidedsecond side seam flap 40 with a perimeter defined by sides 26, 44, 46,48 is secured to an opposite side of the front panel 20. A five-sidedclosure flap 50 with a perimeter defined by sides 52, 28, 56, 57, 58 issecured to an opposite side of the front panel 20 from the rear panel10.

[0004] Envelopes are typically formed by inserting the blank 100 into ahigh speed envelope forming machine (not shown), such as a machinemanufactured by Smith. FIG. 2 illustrates a partially formed envelope200 using the blank 100 of FIG. 1. The side seam flaps 30, 40 have beenfolded over approximately 180 degrees using mechanical equipment. Anadhesive layer 70, 80, 90 is illustrated applied to the flaps 30, 40,50. The adhesive layer 70, 80 on the two side seam flaps 30, 40 have atop perimeter 78, 88 that is illustrated some distance D1 below the topperimeter 38, 48 of the two side seam flaps 30, 40. In conventionalenvelopes the adhesive layers 60, 70 can not extend beyond the topperimeter 38, 48 of the two side seam flaps 30, 40 because ofdifficulties in stacking or shingling the envelopes (discussed in moredetailed with the description of the invention) after making them.

[0005]FIG. 3 illustrates an envelope 300 formed from the partialenvelope of FIG. 2. The rear panel 10 is folded approximately 180degrees and placed in contact with the adhesive layers 70, 80 of the twoside seam flaps 30, 40. Typically the rear panel 10 is mechanicallypressed against the two side seam flaps 30, 40. As illustrated in FIG. 3when the envelope 300 is formed the adhesive layers 70, 80 does notextend beyond the top perimeter 14 of the rear panel 10.

[0006]FIG. 4 illustrates at least one problem of conventional envelopes300. FIG. 4 is a side elevation view of FIG. 3. Typically conventionalenvelopes 300 are filled using insertion machines (not shown). As FIG. 4illustrates in a conventional envelope the rear panel 10 is not securedto the top perimeter 38, 48 of the two side seam panels 30, 40. A gap 60is formed between the rear panel 10 and the two side seam panels 30, 40during the envelope 300 filling operation. This gap 60 can result inproblems with the envelope filling operation (not shown). For example,the filling equipment can become jammed if an insert (not shown) getsstuck in the gap 60. Delays resulting from clearing jammed equipment andthe cost of destroyed envelopes and inserts increase the cost ofpreparing the mailings. What is needed is an improved envelope andmethod of forming an envelope to minimize the gap 60 and improveinserting operations.

SUMMARY OF THE INVENTION

[0007] An envelope formed from a single blank with a front panel, rearpanel, two side flaps, and a closure flap. The two side seam flaps arefolded inward and an adhesive layer is secured to the two side seamflaps and the closure flap. The adhesive layer extends to at least thetop perimeter of the two side seam flaps and may even extend beyond thetop of the perimeter of the rear panel. The rear panel is folded andsecured along substantially the entire length of the two side seamflaps. The envelope is then placed under a drier to dry any of theadhesive that extends beyond the upper perimeter of the two side seamflaps and the upper perimeter of the rear panel. The envelope is thenprocessed and stacked using conventional equipment.

BRIEF DESCRIPTION OF THE FIGURES

[0008] The invention is described below in more detail. The inventioncan be best understood by reading the detailed description of theinvention in conjunction with the figures. Throughout the figures thevarious features of the figures are marked with reference numbers.

[0009]FIG. 1 is a plan view of a prior art envelope blank.

[0010]FIG. 2 is a partially formed enveloped from the blank of FIG. 1.

[0011]FIG. 3 is a plan view of a prior art envelope formed from theblank of FIG. 1.

[0012]FIG. 4 is a side elevation view of FIG. 3.

[0013]FIG. 5 is a plan view of a partially formed envelope according tothe invention.

[0014]FIG. 6 is a plan view of an envelope formed according to theinvention.

[0015]FIG. 7 is side elevation view of FIG. 6.

[0016]FIG. 8 is a schematic flow chart of a method of forming theenvelope according to the invention.

[0017]FIG. 9 illustrates prior art envelopes shingled with each other.

[0018]FIG. 10 illustrates envelopes formed according to the inventionshingled with each other.

DETAILED DESCRIPTION OF THE INVENTION

[0019]FIG. 5 illustrates an exemplary partially formed envelope 500according to the invention. The partially formed envelope 500 is formedfrom an envelope blank. It is to be understood that the blank can beformed from any suitable substrate using any suitable method. The blankcomprises a four sided front panel 120 with a perimeter defined by sides118, 122, 126, 128. A four sided rear panel 110 with a perimeter definedby sides 112, 114, 116, 118 is secured to the front panel 120 along side118. A first side seam flap 130 with a perimeter defined by sides 132,134, 122, 138 is secured to one side of the front panel 120. A secondside seam flap 140 with a perimeter defined by sides 126, 144, 146, 148is secured to an opposite side of the front panel 120. A closure flap150 with a perimeter defined by sides 152, 128, 156, 157, 158 is securedto an opposite side of the front panel 120 from the rear panel 110. FIG.5 is illustrated with the side seam flaps 130, 140 have been folded overapproximately 180 degrees from the front panel 120. Typically the sideseam flaps 130, 140 are folded using mechanical equipment or othersuitable means.

[0020] An adhesive layer 170, 180, 190 is illustrated applied to theflaps 130, 140, 150. The adhesive layer 170, 180 on the two side seamflaps 130, 140 have a top perimeter 178, 188 that is illustrated somedistance D2 above the top perimeter 138, 148 of the two side seam flaps130, 140. Unlike conventional envelopes 300, according to the inventionthe adhesive layers 160, 170 can extend beyond the top perimeter 138,148 of the two side seam flaps 130, 140 as discussed in more detailedbelow.

[0021]FIG. 6 illustrates an envelope 600 formed according to theinvention from the partial envelope of FIG. 5. The rear panel 110 isfolded approximately 180 degrees from the front panel 120 and placed incontact with the adhesive layers 170, 180 of the two side seam flaps130, 140. In an exemplary method, the rear panel 110 is mechanicallypressed against the two side seam flaps 130, 140. It is to be understoodthat other suitable means of securing the rear panel 110 to the two sideseam flaps 130, 140 may be used. As illustrated in FIG. 6 when theenvelope 600 is formed the adhesive layers 170, 180 extends beyond thetop perimeter 114 of the rear panel 110.

[0022]FIG. 7 illustrates at least one advantage of problem of theenvelope 600 formed according to the invention. FIG. 7 is a sideelevation view of FIG. 6. The rear panel 110 is secured to the topperimeter 138, 148 of the two side seam panels 130, 140. Substantiallyno gap is present between the rear panel 110 and the two side seampanels 130, 140 thus improving the envelope filling operation (notshown).

[0023]FIG. 8 illustrates an exemplary schematic flow chart 800 forforming an envelope according to the invention. An envelope blank 805 isfolded in a first folding apparatus 810. An adhesive is applied to thetwo side seam flaps 130, 140 and optionally to the closure flap 150 byan adhesive apparatus 820. The rear panel 110 is then secured to theside seam flap 130, 140 by an apparatus 830 as described above. Theformed envelope is then dried in a drying unit 840. It is to beunderstood that the drying unit 830 can be of any suitable type, forexample convection heat, to dry the adhesive layer 170 and 180. Inparticular the drying unit 840 should be operated to dry any portion ofthe adhesive layer 170, 180 that extends beyond the upper perimeter 114of the rear panel. In addition to improving the inserting operation ofthe finished envelope as described above, the drying of the adhesivelayer 170, 180 offers at least one advantage in mass production ofenvelopes as discussed below.

[0024]FIG. 9 illustrates a conventional envelope manufacturing techniquecalled shingling. In shingling a first envelope 905 is stacked orshingled onto a second envelope 910. The space D3 between two shingledenvelopes 905, 910 is illustrated. In contrast, FIG. 10 illustrates thespace D4 between the shingles if the adhesive layer 170, 180 are driedprior to shingling according to the invention. It is to be understoodthat without the drying step according to the invention that no portionof the top envelope 905 could contact the adhesive layer 170, 180 thatextends above the upper perimeter of the rear panel 110. A comparison ofFIGS. 9 and 10 illustrate that the drying step according to theinvention allows two envelopes 905, 910 to be shingled closer together,i.e. distance D4 is smaller than distance D3, thus improvingmanufacturing speed.

[0025] The invention has been illustrated and described in detail withrespect to exemplary embodiments of the invention. Accordingly thedescription is intended for purposes of illustrating and teaching theinvention rather than limiting the invention. Given the above detaileddescription, one skilled in the art will recognize alternativeembodiments to the invention. These alternative embodiments areconsidered to be part of the invention. The scope of invention is to bedetermined by the following claims.

1. An envelope comprising: a front panel; a closure flap secured to said front panel; two side flaps secured to opposite sides of said front panel; and a rear panel secured to said front panel on an opposite side of said closure flap wherein said rear panel is secured by an adhesive material to said two side flaps, and wherein the rear panel is secured to the perimeter of said side flaps nearest to said closure flap.
 2. The envelope of claim 1 wherein the adhesive material extends at least some distance past the perimeter of said side flaps and wherein said adhesive material is in contact with at least some portion of said front panel.
 3. The envelope of claim 2 wherein said adhesive material extends past the upper perimeter of said front panel and is contact with at least some portion of said closure flap.
 4. The envelope of claim 1 wherein said front panel, said rear panel, and said side flaps are approximately rectangular in shape.
 5. The envelope of claim 1 wherein said envelope is formed from a single substrate.
 6. The envelope of claim 5 wherein said closure flap, said rear panel, and said side flaps are secured to said front panel along a fold line.
 7. The envelope of claim 1 wherein said front panel has at least one aperture.
 8. The envelope of claim 7 wherein said at least one aperture is at least partially covered by a transparent material.
 9. The envelope of claim 1 wherein an adhesive material is secured to at least some portion of said closure flap.
 10. A method of forming an envelope comprising the steps of: providing a substrate; forming an envelope blank from said substrate comprising a front panel, a closure flap secured to said front panel, two side flaps secured to opposite sides of said front panel; and a rear panel secured to said front panel on an opposite side of said closure flap; folding said two side flaps inward toward said front panel; securing an adhesive material to said side flaps along substantially the entire length of said side flaps to include the perimeter of said side flaps closest to the closure flap; and folding said rear panel and contacting it to said side flaps to secure said rear panel to said side flaps, wherein at least some portion of said rear panel is secured to the upper perimeter of said side flaps closest to the closure flap.
 11. The method of claim 10 further comprising the steps of drying said adhesive material that extends beyond the perimeter of said side flaps.
 12. The method of claim 10 further comprising the step of forming at least one aperture in said front panel.
 13. The method of claim 12 further comprising the step of at least partially covering said at least one aperture with a transparent material.
 14. The method of claim 10 further comprising the step of securing an adhesive material to at least some portion of said closure flap. 